Plastic container and method for the use thereof

ABSTRACT

The invention relates to a method for storing and transporting products, wherein, from plastic, foldable containers are manufactured, in particular injection molded; the foldable containers, at a filling location, are brought in a set-up condition and are filled with products; the filled containers are transported to a position of use; the foldable containers are emptied and are collapsed; the containers, in collapsed condition, are returned to the filling location; and the containers are cleaned and reused. The invention further relates to a foldable container which is injection molded from plastic in one piece with integrated hinges, and to specific methods for use of such plastic container.

This application is the U.S. National Phase of International ApplicationNumber PCT/NL02/00245 filed on 12 Apr. 2002, which is incorporatedherein by reference.

BACKGROUND OF THE INVENTION

The invention relates to a method for storing and transporting products.Such a method is known from practice.

In this known method, for instance French fries in frozen condition arepackaged in a plastic bag, which is closed off and subsequently packagedin a cardboard outer box. In these packages, the French fries are storedin cold storage plants and transported to a user, who takes the Frenchfires from the package and subsequently discards the package, prior towhich this has to be separated into plastic and cardboard.

It is further known to package products, for instance fresh fish, inplastic crates. These plastic crates are reused, but take up aparticularly great deal of space, full as well as empty, for storage andtransport. Moreover, these crates are destroyed after their economiclife span.

The object of the invention is to provide a method of the type describedin the preamble, wherein the above-mentioned drawbacks of the knownmethods are avoided, while maintaining their advantages.

SUMMARY OF THE INVENTION

With a method according to the invention, in a particularly economicaland environmentally friendly manner, packaging, storage and transport ofproducts of a diverse nature can be provided for. The foldablecontainers render it possible to package and handle products whether ornot in bulk, while returning and storing empty containers takes upparticularly little space. The containers can easily be cleaned and bereused. It is preferred that the containers, after having reached theend of their economic and/or technical life span, are ground orotherwise reduced, after which the thus obtained plastic parts arereused for again manufacturing a container for use within the invention.

The containers for use within the invention are preferably injectionmolded in one piece, with integrated hinges, so that no assembly stepsare necessary and it is prevented that, during use, parts of thecontainers become separated from each other. Additionally, in thismanner, fragile parts are further avoided.

Covering the container after it has been filled offers the advantagethat the products are particularly well protected. Use of foil which isfixed, in particular sealed, onto or near the upper side on thecontainer, offers the advantage that such a covering can be appliedrapidly and readily, does not yield any packaging and is further easy toindividualize for the respective products. Further, other coverings canalso be used, such as lids, and other manners of fixation can beapplied, for instance gluing.

The invention further related to the packaging of products in a plasticcontainer.

With such a method, in a particularly simple and safe manner, productscan be packaged, shielded from the surroundings. The foil can be easilyprinted for individualizing the contents of the container and does notyield any packaging.

The plastic containers are preferably cleaned, in particular sterilized,at each cycle of use, to which end preferably steam is used.

The invention further relates to a foldable container.

Such a container offers the advantage that it can be manufactured andused in a simple and relatively low-cost manner. Assembly steps arepractically not necessary. Additionally, the advantage is therebyobtained that no parts can come loose unintentionally, which mightotherwise render the container unusable.

Such a container can be injection-molded substantially flat, so that aparticularly simple injection mold can be used. Additionally, relativelysimple injection-molding machines will suffice. As a result, thecontainer can be manufactured in a simple and relatively inexpensivemanner. The specific construction with the lips on the end walls offersthe advantage that a container is obtained which is still relativelystiff and which can be collapsed particularly compactly.

The invention further relates to the use of a foldable plasticcontainer.

Such use of a foldable plastic container offers the advantage that, in asuitable manner, products can be packaged, stored and transported, whilethe packaging, i.e. the container in empty condition, takes uprelatively little space. The plastic containers are preferably used afew to many cycles, after which they are reused for manufacturing new,comparable containers.

The invention further relates to the use of plastic containers.

In such use, the advantage is achieved that products are particularlywell packaged and protected against influences from the outside.Especially with products sensitive to ambient conditions, such asperishables, in particular food, this is particularly advantageous.

In the additional subclaims, further advantageous embodiments ofmethods, devices and methods of use according to the invention aregiven. To clarify the invention, embodiments thereof will be furtherelucidated with reference to the drawing.

BRIEF DESCRIPTION OF TILE DRAWINGS

In the drawing:

FIG. 1 schematically shows, in perspective view, a set up containeraccording to the invention;

FIG. 2 schematically shows, partly in perspective view, a containeraccording to FIG. 1, in flat condition, immediately afterinjection-molding;

FIG. 3 schematically shows, in enlargement, a detail of a connectionbetween an end wall of a container according to FIGS. 1 and 2, in set-upcondition for use;

FIG. 4 schematically shows, in cross section, a pair of a containeraccording to the invention, in collapsed condition;

FIG. 5 schematically shows a detail of a covering fixed to an upperlongitudinal edge of a container according to the invention;

FIG. 6 schematically shows a detail of a connection between an end walland a side wall; and

FIG. 7 schematically shows a cycle of use of a container according tothe invention.

DETAILED DESCRIPTION OF THE INVENTION

In this description, identical or corresponding parts have identical orcorresponding reference numerals. In this description, the startingpoint in each case are plastic containers in the form of crates. It willbe clear that these can be designed in many variants, particularly as tosize, plastics used and mixtures thereof, and constructions of, forinstance, bottom and walls, all within the scope of the invention asoutlined by the claims. In this description, containers the use thereofand methods will be described on the basis of an example, viz, thepackaging of foods, in particular French fries and the like. Theinvention should not, however, be construed as being limited thereto.Additionally, within the containers, subpackages can be used, forinstance portion packages or the like.

FIG. 1 schematically shows, in perspective view, an injection moldedplastic crate 1 according to the invention, comprising a tray-shapedbottom 2, two end walls 4 connected thereto via first film-hinges 3, andtwo side walls 6 connected to the bottom via send film-hinges 5. Inset-up condition, the walls 4, 6 define an inner space 7 which is openat the top via a removal opening 8. The walls 4, 6 abut each other bytheir short sides, thereby forming ribs or connecting seams 9, which arepreferably closed, for instances by suitable sealing means such asintegrally injection-molded backs, flaps or the like.

FIG. 2 represents a corner of a bottom 2, having connected thereto apart of an end wall 4 and a side wall 6 as well as the first and secondfilm hinges 3, 5. The bottom 2 comprises upright longitudinal edges 10,11, while the end walls 4 and the side walls 6, like the bottom, aretray-shaped. In this embodiment, with the crate 1 set up, the closedwall parts 12, 13 of the walls 4, 6 face the inner space 7. The sidewall 6 is connected through the second hinge 5 to the free upper edge ofthe respective longitudinal edge 11 of the bottom 2, and, for clarity'ssake, is represented in a relatively thick and broad manner. It will beclear that the side wall, with the aid of this hinge 5, can be swungboth to a vertical position, at least approximately at right angles tothe bottom 2, and further, so as to lie flat on the bottom 2, as isindicated in FIG. 4. The first film hinge 3 is formed by a lip 16,limited on both sides by a subhinge 14, 15 of the living hinge type,i.e. an integrally injection-molded hinge. The first subhinge 14 isconnected to the bottom 2 near the lower side of the respectivelongitudinal edge 10, i.e. at a height approximately equal to the closedbottom surface 2A. The second sub-hinge 15 is connected to the end wall4, approximately in the plane of the closed wall part 12 thereof. Thelip 13 has a width X which is chosen such that is at least approximatelyequal to and preferably somewhat greater than the height of thelongitudinal edge 10 of the bottom 2. The purpose of this will beelucidated later.

As is clear from FIG. 2, the container 1 can be injection-moldedsubstantially flat. This requires a relatively simple mold and injectionmolding device. After the container 1, as shown in FIG. 2, is taken fromthe mold, preferably when it is still warm, the lip 16 of each end wall4 is folded against the adjacent longitudinal edge 10 and fixed againstit, for instances by welding, gluing a suitable clamped joint or snapconnection or the like. In FIG. 3, this connection 18 is represented bya black cube. The first subhinge 14 only needs to allow bending a singletime, and therefore only needs to be a (warm) deformable wall element.Then, the second subhinge 15 is brought above the free upper edge 17 ofthe respective longitudinal edge 10 and the end wall 4 extends abovethat longitudinal edge 10 and the bottom 2. From this position,represented in broken lines in FIG. 3, which is the position of the endwall 4 when the crate has been set up, this wall 4 can be swung in thedirection of the bottom 2 and be received between the longitudinal edges10, 11, against the bottom surface 2A, as is shown in uninterruptedlines in FIG. 3. Subsequently, in a manner described earlier, the sidewall 6 can be folded thereover, as is shown in FIG. 4, so that acompactly folded crate 1 is obtained.

FIG. 6 shows, in cross-sectional side view, an upper corner or a plasticcrate 1, in which the side wall 6 and an abutting end wall 4 are clearlyvisible. In the longitudinal edge 19 of the end wall 4, an opening 20 isprovided a pin 21, slightly inclining in the direction of the bottom 2.With a crate 1 set up, the pin 21 extends through the opening 20, sothat the side wall 6 is connected to the end wall 4. When the crate 1 islifted by the end walls 4, the wall parts 4, 6 are pulled against eachother even more tightly. The pin 21 and the opening 20 are preferablyself-directing. The longitudinal edge 22 of the side walls 6, for thatmatter, is preferably somewhat higher that the longitudinal edge 11 ofthe bottom of the bottom 2. With the crate 1 set up, the respectivelongitudinal edges 10 of the bottom 2, against the closed wall parts 12of the end walls 4, so that further pivoting of the end walls 4 isprevented. Additionally, also between these longitudinal edges 22 andthese wall parts 12, couplings means such as the pin 21 and hole 20shown, can be disposed, optionally instead of those shown in FIG. 6.With such a connection, it is preferred that also the longitudinal edge22 of the side walls 6 that faces away from the bottom extends above theend walls, and the coupling means are designed such that when liftingthe crate by the side walls 4, these are pulled against the longitudinaledges 22 of the side walls, while upon lifting by the side walls 6,retention is obtained with the aid of the coupling means, for instanceby inverting the direction of inclination of the pins 21. Naturally,also various other coupling means can be provided for coupling the sidewalls 6 and the end walls 4.

FIG. 5 shows an upper corner of a crate 50, which is manufactured fromplastic. The crate 50 can be foldable, as a crate 1 according to FIGS.1–4 and 6, but it can also have a fixed shape. One the upper edge 51,which is preferably of flat design, a foil 52 is sealed or otherwiseconnected, for instance glued, welded or the like. The foil ispreferably substantially gas-and liquid-tight, and so is, preferably,the crate 50, and can be provided with a print (not shown) matching theproducts 53 brought into the crate 50, for instance French fries. Thefoil closes off the entire upper side and thus forms a good barrieragainst external influences on the products 53. Such a foil can simplybe applied in an automatic manner.

FIG. 7 schematically shows a method for the use of crates, in particularcollapsible plastic crates 1 for packaging, storing and/or transportingproducts. Plastic material, for instance a mixture of suitable polymers,which are resistant to temperatures below 0 degrees Centigrade, issupplied from a side 60 to a storage buffer 61. It will, for thatmatter, be clear to any skilled person which plastic materials can ormust be used, depending on the requirements for use of the crates 1.From the buffer 61, plastic is supplied to an injection-molding device62, in which the crates 1 are injection molded. After withdrawal, thecrates are prepared for use, in particular by fixing the lips 16 againstthe longitudinal bottom edges 10. Subsequently, prior to use, the crate1 is set up in a set-up station 63, after which the crates 1 are filledin a filling station 64. Thereupon, the crates 1 can be closed off in aclosing station 65, for instance by sealing as described earlier, or byfitting a different, suitable closing means, such as a cover. Fromthere, or from the filling station 64, the crates 1 can be stored and/ortransported, indicated with the number 66. At a suitable position of use67, at a desired moment, the crates are then taken out of storage 66 andemptied, for use of the products, after which the crates 1 are collapsedin a folding station 68 for returning the empty crates 1.

From the folding station 68, the crates 1 can be brought to a cleaningstation, 69, where the crates are cleaned. To that end, for instancesteam can be used, which is favorable for the environment and in termsof practical cleaning. Naturally, other techniques can also be used.When the crates are used, for instance, for perishables such as food,for medical equipment and the like, it is further advantageous when thecrates are disinfected and optionally sterilized, in a mannerappropriate therefor. Then, the crates 1 are ready to be refilled in thefilling station 64, after having been set up in the set-up station 63.Naturally, cleaning can also be done after set-up.

The crates can be stacked into each other with the side walls 6 and/orthe end walls 4, whereby the bottom 2 is received between the side wallsand can provide further stability.

From the folding station 68, or possibly from the user station 67, thecrates 1 can also be transported to a recycle unit 70, where the cratesare ground or otherwise granulated for reuse of the plastic material,which can be mixed in the buffer 61 with other, and optionally new,material. Such recycling can be done at the end of the economic and/ortechnical life span of a crate 1 or at any other suitable or desiredmoment. As the crates are thus repeatedly reused, practically nomaterial is lost, which is environmentally and economicallyadvantageous. Only very little new material needs to be supplied.

The invention is no way limited to the embodiments represented in thedescription and the drawings. Many variations thereon are possiblewithin the scope of the invention as outlined by the claims.

For example, the crates 1 can be designed to be collapsible in adifferent manner for use within a method according to the invention, orbe designed to permit partial disassembly. Non-folding crates are alsoused in a method according to the invention as schematically shown inFIG. 7. Naturally, setting up and collapsing the crates in then omitted.Further, the hinges and other connecting constructions can be designedin a different manner. By using a tray-shaped bottom, the advantage isachieved that a stable bottom is obtained inside of which at least theend walls 4 can be folded. However, it is also possible to couple theend walls directly with a single hinge to the wall part 2A of thebottom, and then to leave out the upright longitudinal edge 10, or togive the longitudinal edge 10 only a lesser height and to connect it,via a hinge, to the adjacent longitudinal edge of the end wall 4, at asuitable height, such that the end wall can still be pivoted against thebottom 2, 2A. In the upright position, the end wall will then to someextent reach outside the contour defined by the bottom plate 2A.

These and many comparably variations are deemed to fall within the scopeof the invention as outlined by the claims.

1. A method for storing and transporting products comprising the stepsof: injection molding foldable containers from plastic, said containersbeing in one piece with integrated hinges, wherein the containers areprovided with a tray-shaped bottom with upright edges, two end walls andside walls, wherein the bottom comprises four upwardly extending edgesfrom a bottom plate, wherein the end walls are at least substantiallyfoldable within the bottom between said edges, and the side walls aresubstantially foldable over the end walls, wherein the end walls areeach integrally connected to said bottom by a respective lip provided atthe outside of said bottom, each of said lips being respectivelyconnected to an outside surface of one of said upwardly extending edgesof said bottom; folding said containers whereby said two end walls ofthe container are folded within the bottom between the edges, andwhereby the side walls of the container are folded over the end walls;filling the foldable containers with products at a filling location;transporting the filled containers to a position of use; emptying andcollapsing the foldable containers after use; and returning thecontainers, in collapsed condition to the filling location, wherein thecontainers are cleaned and are reused.
 2. A method according to claim 1,wherein the containers are filled and emptied a few times, after whichthe container is recycled by granulation and injection molding afoldable container again.
 3. A method according to claim 1, wherein thecontainers, after filling, are covered by a covering which engages atleast end walls and/or side walls of the container.
 4. A methodaccording to claim 3, wherein the containers are covered by a foil whichis sealed onto the side walls and/or the end walls of the container. 5.A method according to claim 4, wherein the foil is sealed on the upperlongitudinal edges of the end walls and the side walls of the container,for forming a complete sealing of the open upper side of the container.6. A method according to claim 1, wherein the containers aremanufactured from a plastic, resistant to temperatures below 0 degreesCentigrade, which plastic is recyclable and, additionally, sealablethrough thermal welding, heat sealing, or the like, or to which hot- orcold-melt glues adhere.
 7. A method according to claim 1, wherein,between cycles of use, the containers are cleaned with steam, wherebythe containers are sterilized.
 8. A foldable container, which isinjection-molded from plastic in one piece with integrated hinges,wherein the container is provided with a bottom, two end walls and twoside walls, wherein the bottom is tray-shaped and comprises fourupwardly extending edges from a bottom plate, wherein the end walls areat least substantially foldable within the bottom between said edges,and the side walls are substantially foldable over the end walls,wherein the end walls are each integrally connected to said bottom by arespective lip provided at the outside of said bottom, each of said lipsbeing respectively connected to an outside surface of one of saidupwardly extending edges of said bottom.
 9. A foldable containeraccording to claim 8, wherein the container is injection-moldedsubstantially flat, and wherein said lips, after injection molding, arefixed to the sides of the bottom, such that the connections between thelips and the respective end walls are situated above the upperlongitudinal edge of the bottom on the respective sides and form hingemeans for the end walls.
 10. A foldable container according to claim 8,wherein the side walls and the end walls are also substantiallytray-shaped, with the container set up, the end walls and/or the sidewalls extend at least partly outside the outer contour of the bottom,such that a plurality of said containers can be stacked by positioningthe bottom of a superjacent container between the side walls and the endwalls of a subjacent container, the side walls and/or the end walls ofthe superjacent container resting on those of the subjacent container.11. A foldable container according to claim 8, wherein the end wallshave a width being approximately equal to the corresponding width of thebottom, and the side walls have a length greater than the correspondinglength of the bottom, such that, with the container set up, the parts ofthe side walls protruding on both sides outside the bottom abut thesides of the end walls, while coupling means are provided for couplingthe end walls with the side walls.
 12. A foldable container according toclaim 11, wherein the coupling means are arranged for form- orforce-closed coupling as a detachable pin-hole connection.
 13. Afoldable container according to claim 8, wherein the side walls and/orthe end walls of the container are provided with cooperating sealingmeans which, with the container set up, provide substantially closedribs.
 14. A foldable container according to claim 8, wherein thecontainer is manufactured from recyclable and sterilizable plastic. 15.A one-piece injection molded container comprising: a tray shaped bottomhaving a bottom plate and a peripheral edge extending upwardly from saidbottom plate; a foldable end wall integrally connected to an outersurface of said peripheral edge, said end wall having a first sub-hingeconnected to a lower portion of said peripheral edge outer surface, alip extending from said first sub-hinge and fixed to said peripheraledge outer surface, a second sub-hinge disposed at an end of said lipopposite said first sub-hinge and a wall part extending from said secondsub-hinge, wherein said wall part is pivotable about said secondsub-hinge between a set-up position, wherein said wall part extendsupwardly from said second sub-hinge substantially perpendicular to saidbottom plate, and a folded position, wherein said wall part is disposedwithin said peripheral edge of said bottom substantially parallel withsaid bottom plate; and a side wall integrally connected to said bottom,said side wall being foldable over said end wall when said end wall isin said folded position.
 16. A one-piece injection molded container asdefined in claim 15, wherein said end wall and said side wall include anintegral lock for locking said end wall to said side wall when said endwall is in said set-up position.
 17. A one-piece injection moldedcontainer as defined in claim 16, wherein said integral lock comprisesan integral pin formed on one of said end wall and said side wall and anopening formed in the other of said end wall and said side wall, saidpin being received in said opening for locking said end wall to saidside wall when said end wall is in said set-up position.